High-performance electroactive polymer transducers

ABSTRACT

Transducers employing electroactive polymer films are disclosed.

CROSS-REFERENCE

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/361,703 filed Feb. 24, 2006, which is a continuation-in-partof U.S. patent application Ser. No. 11/085,798 filed Mar. 21, 2005, andis a continuation-in-part of U.S. patent application Ser. No. 11/085,804filed Mar. 21, 2005, and claims the benefit of U.S. patent applicationSer. No. 60/776,861 filed Feb. 24, 2006, the contents of which areincorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention is directed to electroactive polymer transducersand their applications.

BACKGROUND

A tremendous variety of devices used today rely on actuators of one sortor another to convert electrical energy to mechanical energy. Theactuators “give life” to these products, putting them in motion.Conversely, many power generation applications operate by convertingmechanical action into electrical energy. Employed to harvest mechanicalenergy in this fashion, the same type of actuator may be referred to asa generator. Likewise, when the structure is employed to convertphysical stimulus such as. vibration or pressure into an electricalsignal for measurement purposes, it may be referred to as a transducer.Yet, the term “transducer” may be used-to generically refer to any ofthe devices. By any name, a new class of components employingelectroactive polymers can be configured to serve these functions.

Especially for actuator and generator applications, a number of designconsiderations favor the selection and use of advanced electroactivepolymer technology based transducers. These considerations includepotential force, power density, power conversion/consumption, size,weight, cost, response time, duty cycle, service requirements,environmental impact, etc. Electroactive Polymer Artificial Muscle(EPAM™) technology developed by SRI International and licenseeArtificial Muscle, Inc. excels in each of these categories relative toother available technologies. In many applications, EPAM™ technologyoffers an ideal replacement for piezoelectric, shape-memory alloy (SMA)and electromagnetic devices such as motors and solenoids.

As an actuator, EPAM™ technology operates by application of a voltageacross two thin elastic film electrodes separated by an elasticdielectric polymer. When a voltage difference is applied to theelectrodes, the oppositely-charged members attract each other producingpressure upon the polymer therebetween. The pressure pulls theelectrodes together, causing the dielectric polymer film to becomethinner (the z-axis component shrinks) as it expands in the planardirections (the x and y axes of the polymer film grow). Another factordrives the thinning and expansion of the polymer film. The like (same)charge distributed across each elastic film electrode causes theconductive particles embedded within the film to repel one anotherexpanding the elastic electrodes and dielectric attached polymer film.

Using this “shape-shifting” technology, Artificial Muscle, Inc. isdeveloping a family of new solid-state devices for use in a wide varietyof industrial, medical, consumer, and electronics applications. Currentproduct architectures include: actuators, motors, transducers/sensors,pumps, and generators. Actuators are enabled by the action discussedabove. Generators and sensors are enabled by virtue of changingcapacitance upon physical deformation of the material.

Artificial Muscle, Inc. has introduced a number of fundamental “turnkey”type devices that can be used as building blocks to replace existingdevices. Each of the devices employs a support or frame structure topre-strain the dielectric polymer. It has been observed that thepre-strain improves the dielectric strength of the polymer, therebyoffering improvement for conversion between electrical and mechanicalenergy by allowing higher field potentials.

Of these actuators, “Spring Roll” type linear actuators are prepared bywrapping layers of EPAM™ material around a helical spring. The EPAM™material is connected to caps/covers at the ends of the spring to secureits position. The body of the spring supports a radial orcircumferential pre-strain on the EPAM™ while lengthwise compression ofthe spring offers axial pre-strain. Voltage applied causes the film tosqueeze down in thickness and relax lengthwise, allowing the spring(hence, the entire device) to expand. By forming electrodes to createtwo or more individually addressed sections around the circumference,electrically activating one such section causes the roll to extend andthe entire structure to bend away from that side.

Bending beam actuators are formed by affixing one or more layers ofstretched EPAM™ material along the surface of a beam. As voltage isapplied, the EPAM™ material shrinks in thickness and grows in length.The growth in length along one side of the beam causes the beam to bendaway from the activated layer(s).

Pairs of dielectric elastomer films (or complete actuator packages suchas the aforementioned “spring rolls”) can be arranged in “push-pull”configurations. Switching voltage from one actuator to another shiftsthe position of the assembly back and forth. Activating opposite sidesof the system makes the assembly rigid at a neutral point.So-configured, the actuators act like the opposing bicep and tricepsmuscles that control movements of the human arm. Whether the push-pullstructure comprises film sections secured to a flat frame or one or moreopposing spring rolls, etc, one EPAM™ structure can then be used as thebiasing member for the other and vice versa.

Another class of devices situates one or more film sections in a closedlinkage or spring-hinge frame structure. When a linkage frame isemployed, a biasing spring may generally be employed to pre-strain theEPAM™ film. A spring-hinge structure may inherently include therequisite biasing. In any case, the application of voltage will alterthe frame or linkage configuration, thereby providing the mechanicaloutput desired.

Diaphragm actuators are made by stretching EPAM™ film over an opening ina rigid frame. Known diaphragm actuator examples are biased (i.e.,pushed in/out or up/down) directly by a spring, by an intermediate rodor plunger set between a spring and EPAM™, by resilient foam or airpressure. Biasing insures that the diaphragm will move in the directionof the bias upon electrode activation/thickness contraction rather thansimply wrinkling. Diaphragm actuators can displace volume, making themsuitable for use as pumps or loudspeakers, etc.

More complex actuators can also be constructed. “Inch-worm” and rotaryoutput type devices are examples of such. Further description anddetails regarding the above-referenced devices as well as others may befound in the following U.S. patents and/or published patentapplications:

-   -   U.S. Pat. No. 7,064,472 Electroactive Polymer Devices for Moving        Fluid    -   U.S. Pat. No. 7,052,594 Devices and Methods for Controlling        Fluid Flow Using Elastic Sheet Deflection    -   U.S. Pat. No. 7,049,732 Electroactive Polymers    -   U.S. Pat. No. 7,034,432 Electroactive Polymer Generators    -   U.S. Pat. No. 6,940,221 Electroactive Polymer Transducers and        Actuators    -   U.S. Pat. No. 6,911,764 Energy Efficient Electroactive Polymers        and Electroactive Polymer Devices    -   U.S. Pat. No. 6,891,317 Rolled Electroactive Polymers    -   U.S. Pat. No. 6,882,086 Variable Stiffness Electroactive Polymer        Systems    -   U.S. Pat. No. 6,876,135 Master/slave Electroactive Polymer        Systems    -   U.S. Pat. No. 6,812,624 Electroactive Polymers    -   U.S. Pat. No. 6,809,462 Electroactive Polymer Sensors    -   U.S. Pat. No. 6,806,621 Electroactive Polymer Rotary Motors    -   U.S. Pat. No. 6,781,284 Electroactive Polymer Transducers and        Actuators    -   U.S. Pat. No. 6,768,246 Biologically Powered Electroactive        Polymer Generators    -   U.S. Pat. No. 6,707,236 Non-contact Electroactive Polymer        Electrodes    -   U.S. Pat. No. 6,664,718 Monolithic Electroactive polymers    -   U.S. Pat. No. 6,628,040 Electroactive Polymer Thermal Electric        Generators    -   U.S. Pat. No. 6,586,859 Electroactive Polymer Animated devices    -   U.S. Pat. No. 6,583,533 Electroactive Polymer Electrodes    -   U.S. Pat. No. 6,545,384 Electroactive Polymer Devices    -   U.S. Pat. No. 6,543,110 Electroactive Polymer Fabrication    -   U.S. Pat. No. 6,376,971 Electroactive Polymer Electrodes    -   U.S. Pat. No. 6,343,129 Elastomeric Dielectric Polymer Film        Sonic Actuator    -   2006/0290241 Electroactive Polymer Animated Devices    -   2006/0238079 Electroactive Polymers    -   2006/0238066 Electroactive Polymer Generators    -   2006/0158065 Electroactive Polymer Devices for Moving Fluid    -   2006/0119225 Electroactive Polymer Motors    -   2005/0157893 Surface Deformation Electroactive Polymer        Transducers    -   2004/0263028 Electroactive Polymers    -   2004/0217671 Rolled Electroactive Polymers    -   2004/0124738 Electroactive Polymer Thermal Electric Generators    -   2002/0175598 Electroactive Polymer Rotary Clutch Motors    -   2002/0122561 Elastomeric Dielectric Polymer Film Sonic Actuator        Each of these documents. is incorporated herein by reference in        its entirety for the purpose of providing background and/or        further detail regarding underlying technology and features as        may be used in connection with or in combination with the        aspects of present invention set forth herein.

While the devices described above provide highly functional examples ofEPAM™ technology transducers, there continues to be an interest indeveloping high performance EPAM™ transducers.

SUMMARY OF THE INVENTION

Transducers according to the present invention offer improved poweroutput. Various transducer configurations are described that are uniquein their ability to be tuned for high-frequency applications. Onlythrough appreciation of the teachings herein would one be motivated toattempt such tuning, as prior authority has taught away from suchpossibility.

According to the present invention, it has been determined that oneclass of EPAM™ transducers can be run or “clocked” at high rates (e.g.,at or above 50 Hz, more typically up to 100 Hz, and even up to about 1KHz) without detrimental decrease in output stroke relative to typicallylower speed DC switched applications. In other words, even at higherfrequencies, the theoretical performance of such systems substantiallymatches actual performance (i.e., driven at higher frequencies, theselected transducers essentially offer performance at their theoreticallimit).

This class of transducers includes those in which the EPAM™ issubstantially unconstrained from compression to yield device output. Inother words, multiple direction components of extension or growth of thematerial contributes to device output. With such architecture, one ormore mass elements are employed so as to provide a spring-mass orspring-mass-damper system which operates at or near a resonance at adesirably high frequency.

The value of high frequency operation is to increase overall devicepower output. When operating at or near a natural resonance frequency,output stroke is maximized (or at least improved relative to a conditionfar departed from the resonance peak). Added to this is that the higherthe frequency, the more working cycles offered. As such, the assigneehereof has produced pumps offering 10× performance improvement. Furtheradvancement is possible as well.

Regarding the physical characteristics of the actuators, in onevariation, frustum-shaped diaphragm actuators are provided in which thetop of the structure includes a cap. The cap may be a solid disc,annular member or otherwise constructed. The cap provides a stableinterface between opposing frustums and/or for a mechanical preloadedelement such as a spring. Such structures are farther described below.In addition to such teachings, according to the present invention, themass of the cap is set in order to provide a system that operates atresonance or has a band of operation near resonance delivering desiredperformance at desirably high frequencies.

In operation, compression of the EPAM™ material causes growth around thecap such that it is displaced by the preload applied to the system in adirection with at least a component perpendicular to the device frame.In another application, no preload is employed, but rather an inertialload of the mass provides for system return during oscillation.

As for other actuator architectures applicable to high-speed use, someexamples are known. Specifically, U.S. Pat. No. 6,545,384 describesplanar devices in which a plurality of struts surrounding EPAM™ materialhinge or flex relative to one another to change configuration to yielddevice mechanical output and/or accept mechanical input to convert toelectrical output in a generator configuration. As an actuator,compression of the EPAM™ upon voltage application causes growth in adifferent direction of a plane defined by a stretched electroactivepolymer material diaphragm. As actuators, because these devicesefficiently use the multi-directional expansion of the EPAM™, they areamendable to high-frequency tuning according to the present invention.Such use is accomplished by tuning the mass of the strut/frame segmentsor another mass element coupled to output features.

In contrast, it is a theory of the inventors hereof that other actuatortypes employing acrylic polymer in the EPAM™ material are not amenableto such use due to inefficient use of the polymer. In less efficientstructures, such as “spring roll” and deflectable beam and planaractuators (the latter described with respect to FIG. 3 below), materialis not used to drive action (or capture energy) with each availabledirection of material expansion/contraction. Rather, internal lossescompounded by the acrylic's naturally high hysteresis in such actuatorsare believed to account for the prior belief by those with skill in theart that acrylic-based actuator could not perform as presently taught.

In any case, another variation of the invention offers yet anotheractuator architecture suitable for acrylic polymer based high-frequencyuse. In this variation, a unitary flexible frame is provided that flexesto change its 3-dimensional orientation (in contrast to the2-dimensionally constrained or planar actuators described directlyabove). Even when not driven at higher frequencies, the architecture mayoffer particular efficiency in energy output. Still further, its uniqueconfiguration, resembling “flapping” wings when actuated (on one side ofan equilibrium point or through a full range past a bi-stableequilibrium point), offers an advantageous actuator for drivinganimal-like wings.

Especially for high-frequency applications, actuator variationsaccording to the invention are advantageously applied to new rotarymotor configurations described below. The drive members of the subjectmotors may be configured to optimize performance for a particularapplication depending on energy and speed requirements and the number ofdrive members involved.

Whether driven by a high-frequency acrylic based transducer or ahigh-frequency silicone based transducer, in certain embodiments, themotors may be configured to offer a manual-override control feature.Stated otherwise, a new rotary motor architecture is disclosed that maybe set-up for intermittent engagement of drive members in order to offermanual adjustment when drive components are inactive. Such a device maybe employed in low-flow dispensing applications for infusion, perfusion,etc. in which manual intervention to alter flow levels is eitherdesirable or necessary for efficacy and/or safety.

In addition to the various actuator applications involving a purelymechanical output, the EPAM™ actuators of the present invention may beapplied in various lighting applications. Any number of actuators may beemployed to provide actuation to a plurality of reflectors and/or lensessuch that the relative motion between a light source and thereflector/lens assembly creates a variable-angle light reflector. Thereflector assembly is configured such that the resultant reflected lightray is made up of all available light provided by the light source. Byscanning this light over a surface or in a direction at a high rate ofoscillation beyond human perception (>60 Hz), the result is a field ofspecific intensity and design based on the actuation level of the EPAMdevice and the specific design of the reflector system. This system canalso be employed in a deliberately stroboscopic manner to increase theability of the light to be picked up by the human eye. Such a system maybe employed in standard lighting applications driven by 120V AC outletpower as well as in mobile lighting applications, such as in anyself-propelled vehicle (automobiles, planes, ships), flash lights, etc.

Regarding methodology, the subject methods may include each of themechanical activities associated with use of the devices describe aswell as electrical activity. As such, methodology implicit to the use ofthe devices described forms part of the invention. Such methodology mayinclude that associated with running acrylic based EPAM™ transducers asmotors or generators at higher frequencies or power output/generationlevels that currently believed possible. The methods may focus on designor manufacture of such devices. In other methods, the various acts ofmechanical actuation are considered; in still others, the powerprofiles, monitoring of power and other aspects of power control areconsidered. Likewise, electrical hardware and/or software control andpower supplies adapted by such means (or otherwise) to effect themethods form part of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The figures illustrate exemplary aspects of the invention. Of thesefigures:

FIGS. 1A and 1B show opposite. sides of an EPAM™ layer;

FIG. 2 is an assembly view of an EPAM™ layer stack;

FIG. 3 is an assembly view of an EPAM™ planar actuator;

FIGS. 4A and 4B are assembly and perspective views, respectively, of aplanar transducer configuration;

FIG. 5 is a top view of a the device in FIGS. 4A and 4B electricallyconnected for planar actuation;

FIGS. 6A and 6B are assembly and perspective views, respectively, of thetransducer in FIGS. 4A and 4B setup in an alternate, frustumconfiguration for out-of-plane actuation;

FIGS. 7A-7C diagrammatically illustrate the geometry and operation offrustum-shaped actuators;

FIG. 8 is a top view of a multi-phase frustum-shaped actuator;

FIGS. 9A-9D illustrate various embodiments of double frustum transducersof the present invention;

FIG. 10 is a sectional perspective view of a parallel-stacked type offrustum transducer;

FIG. 11 is a side-section view showing an optional output shaftarrangement with a frustum type transducer;

FIG. 12 is a side-section view of an alternate, inverted frustumtransducer configuration;

FIG. 13A is a sectional perspective view of a coil spring-biased singlefrustum transducer; FIG. 13B is a side section view of a coilspring-biased double frustum transducer;

FIG. 14 is a perspective view of a leaf spring-biased single frustumtransducer;

FIG. 15 is a perspective view of a weight-biased single frustumtransducer;

FIG. 16 is a perspective view of frustum-type transducers provided inseries for stroke amplification;

FIGS. 17A and 17B are sectional perspective views showing variations ofa pump employing frustum-type actuators;

FIG. 18 is a sectional perspective view of a double-acting pumpemploying frustum-type actuators;

FIGS. 19A-19C provide views of another type of valve control systemillustrative various different aspect of the present invention;

FIGS. 20A and 20B show sectional views of the system at two operationalstates;

FIGS. 21A, 21B, 21C and 21D show known “bow”, “bowtie” and “spider” typetransducers;

FIGS. 22A-22D show these transducers modified according to an aspect ofthe present invention;

FIGS. 23A-23C show a saddle-shaped actuator in various stages ofactuation; FIG. 24 shows a paired assembly of two such actuatorsillustrating one input/output mode.

FIGS. 25A and 25B show mechanical flight system, in which FIG. 25Aprovides a detail view, and FIG. 25B shows a time-lapse view of actualuse;

FIGS. 26A and 26B provide a schematic illustration of one embodiment ofa lighting system employing a frustum-type actuator of the presentinvention;

FIGS. 27A and 27B provide a schematic illustration of another embodimentof a lighting system employing a frustum-type actuator of the presentinvention;

FIGS. 28A and 28B show perspective and top views of a single-clutchmotor drive system of the present invention employing a stackedtransducer of the present invention;

FIGS. 29A and 29B show perspective and side cross-sectional views of adouble-clutch, single pinion motor drive system of the presentinvention;

FIGS. 30A-30C show perspective, cross-sectional and end views,respectively, of a double-clutch, double-pinion motor drive system ofthe present invention;

FIGS. 31A-31C show cross-sectional views of a single-clutch, lead screwmotor drive system of the present invention;

FIGS. 31A-31C show cross-sectional views of a single-clutch, lead screwmotor drive system of the present invention;

FIGS. 32A-32C show cross-sectional views of a double-clutch, lead screwmotor drive system of the present invention; and

FIGS. 33A and 33B show cross-sectional perspective and side views ofanother pump system of the present invention.

Variation of the invention from that shown in the figures iscontemplated.

DETAILED DESCRIPTION OF THE INVENTION

Various exemplary embodiments of the invention are described below. Anumber of actuator/transducer embodiments are first described. Next,systems optionally incorporating such devices are described. They areprovided to illustrate broadly applicable aspects of the presentinvention.

Transducer Architecture

FIGS. 1A and 1B show opposite sides of an EPAM™ layer 10. The layercomprises dielectric polymer sandwiched between elastic thin filmelectrodes. FIG. 1A shows the side of the layer patterned with “hot”electrodes 12 and 14. Each electrode is connected to a lead 16. FIG. 1Bshows the opposite side of layer 10 patterned with a common “ground”electrode 18 connected to a single lead 16.

As shown in FIG. 2, multiple film layers 10 are stacked and held in astretched state within frame pieces 20. A number of individual EPAM™layers 10 are advantageously stacked to form a compound layer 10′. Doingso amplifies the force potential of the system. The number of layersstacked may range from 2 to 10 or more. Generally, it will be desired tostack an even number of layers so that ground electrodes. are facing anyexposed surfaces to provide maximum safety. In any case, the EPAM™ layeror layers may collectively be referred to as EPAM™ “film.”

With one or more layers of material secured in a frame, the frame may beused to construct a complex transducer mechanism. FIG. 3 shows one suchconstruction as known in the art. Here, individual cartridge sections 22are secured to a secondary or body frame portion 24. Any film frames andintermediate frame member are joined to provided a combined (i.e.,attached with fasteners as shown, bonded together, etc.) frame structure26. A spacer 28 provides an interface for an input/output rod 30received by the frame though guide hole 32. The spacer is attached tothe film via complementary mounts 34 bonded to or clamped the EPAM™ filmwith the spacer.

To actuate a device constructed according to FIG. 3, voltage is appliedto either one of electrodes 12 or 14. By applying voltage to one side,that side expands, while the other relaxes its preload and contracts.

A first device capable of alternatively being set in a frustumarchitecture can be similarly configured and operated. FIGS. 4A and 4Bprovide assembly and perspective view of a transducer 40 that canalternatively be configured for planar actuation (as the device is inFIG. 3) and out-of-plane actuation. As with the device described inreference to the previous figures, frames 20 carry layers 10/10′ withground electrodes facing outward.

Again, individual cartridge sections 22 are stacked with a secondaryframe 24 and spacer 28 therebetween, with the spacer providing aninterface for an input/output rod 30 received by the frame. However,spacer 28 in this configuration is to be attached to the substantiallysquare-shaped cap 42 elements of cartridges 22. A more symmetricalinterface portion offers advantages as will be explained below. FIG. 4Bshows the assembled device. Here, transducer 40 is shown as a completeunit.

As for actuation of the device, FIG. 5 shows a basic circuit diagram inwhich “A” and “B” sides of the circuit are powered relative to ground tocause back and forth movement of rod 30 along an X-axis relative toframe.

In the alternative configuration alluded to above, the same EPAM™ layercartridges can be used to produce a transducer adapted for out-of-planeor Z-axis input/output. FIGS. 6A and 6B illustrate such a device. Heretransducer assembly 50 may employ a thicker body frame 24′. By employingsuch a frame and also omitting the spacer layer, when caps 42 aresecured to one another, they produce deeply concave forms 52 facingopposite or away from one another. To actuate the transducer for simpleZ-axis motion, one of the concave/frustum sides is expanded by applyingvoltage while the other side is allowed to relax. Such action increasesthe depth of one cavity 52 while decreasing that of the other. In thesimplest case, the motion produced is generally perpendicular to a faceof the caps 42.

FIGS. 7A-7C diagrammatically illustrate the manner in which theseconcave/convex or frustum shaped actuators function in a simplified twodimensional model. FIG. 7A illustrates the derivation of the transducerfrustum shape.

A “frustum” is technically the portion of a geometric solid that liesbetween two parallel planes. A frustum is often regarded as the basalpart of a cone or pyramid formed by cutting off the top by a plane,typically, parallel to the base. Naturally, frustum-type actuatorsaccording to the invention may be in the form of a truncated cone,thereby having a circular cross-section, or may employ a variety ofcross-sectional configurations. Depending on their application,desirable alternative cross-sectional geometries include triangular,square, pentagonal, hexagonal, etc. Often, symmetrically shaped memberswill be desirable from the perspective of consistent materialperformance. However, ovaloid, oblong, rectangular or other shapes mayprove better for a given application—especially those that arespace-constrained. Further variation of the subject “frustum”transducers is contemplated in that the top and/or bottom of the form(s)need not be flat or planer, nor must they be parallel. In a most generalsense, the frustum shape employed in the present invention may beregarded as a body of volume that is truncated or capped at an end.Often, this end is the one having the smaller diameter orcross-sectional area.

Whether conical, squared, ovaloid, or otherwise when viewed from aboveor from the side, a truncated form 60 is provided. It may formed throughmodifying existing diaphragm actuator configurations by capping the top(or bottom) of the structure. When under tension, the cap 42 alters theshape the EPAM™ layer/layers 10/10′ would take. In the example where apoint load stretches the film, the film would assume a conical shape (asindicated by. dashed lines define a triangular top 62). However, whencapped or altered to form a more rigid top structure, the geometry istruncated as indicated in solid lines 64 in FIG. 7A.

So-modified, the structure's performance is fundamentally altered. Forone, the modification distributes stress that would otherwiseconcentrate at the center of structure 66 around a periphery 68 of thebody instead. In order to effect this force distribution, the cap 42 isaffixed to the EPAM™ layers. An adhesive bond may be employed.Alternatively, the constituent pieces may be bonded together using anyviable technique such as thermal bonding, friction welding, ultrasonicwelding, or the constituent pieces may be mechanically locked or clampedtogether. Furthermore, the capping structure may comprise a portion ofthe film which is made substantially more rigid through thermal,mechanical or chemical techniques—such as vulcanizing.

Generally, the cap section will be sized to produce a perimeter ofsufficient dimension/length to adequately distribute stress applied tothe material. The ratio of the size of the cap to the diameter of theframe holding the EPAM™ layers may vary. Clearly, the size of the disc,square, etc. employed for the cap will be larger under higherstress/force application. The degree of truncation of the structure isof further importance to reduce the aggregate volume or space that thetransducer occupies in use, for a given amount of pre-stretch to theEPAM™ layers as compared to point-loaded diaphragm material cones,pressure biased domes, etc. Furthermore, in a frustum type diaphragmactuator, the cap or diaphragm element 42 may serve as an activecomponent (such as a valve seat, etc.) in a given system.

With the more rigid or substantially rigid cap section formed or set inplace, when EPAM™ material housed by a frame is stretched in a directionperpendicular to the cap (as seen by comparing the EPAM/frameconfigurations as shown in FIGS. 6A/6B), it produces the truncated form.Otherwise the EPAM™ film remains substantially flat or planar.

Returning to FIG. 7A, with the cap 42 defining a stable top/bottomsurface, the attached EPAM™ polymer sides 10/10′ of the structure assumean angle with respect to the cartridge frame (not shown in FIGS. 7A-7C).When the EPAM™ is not activated, the angle α may range between about 15and about 85 degrees. More typically it will range from about 30 toabout 60 degrees. When voltage is applied so that the EPAM™ material iscompressed and grows in its planar dimensions, it assumes a second angleβ in about the same range plus between about 5 and about 15 degrees.Optimum angles may be determined based on application specifications.

Single-sided frustum transducers are within the contemplated scope ofthe present invention as well as double-sided structures. For preload,single-sided devices employ any of a spring interfacing with the cap(e.g., a coil, a constant force or roll spring, leaf spring. etc.), airor fluid pressure, magnetic attraction, a weight (so that gravityprovides preload to the system), or a combination of any of these meansor the like. In yet another variation, a mass is provided such that in acyclic application, the mass is tuned to offer an inertial bias. Themass of the system will be tuned so as to offer maximum displacement ata desired frequency of operation. Ideally, when a constant operatingfrequency can be employed, the size of the mass is selected forresonance by modeling the system as a mass-spring system ormass-spring-damper mechanical system. In variable frequencyapplications, system may be designed so that the peak performance rangecovers a broader section of frequencies, e.g. from about 0.1 to about300 Hz.

In double-sided frustum transducers, one side typically provides preloadto the other. Still, such devices may include additional biasfeatures/members. FIG. 7B illustrates the basic “double-frustum”architecture 70. Here, opposing layers of EPAM™ material or one side ofEPAM™ film and one side of basic elastic polymer are held together undertension along an interface section 72. The interface section oftencomprises one or more rigid or semi-rigid cap element(s) 42. However, byadhering two layers of the polymer together at their interface, thecombined region of material, alone, offers a relatively stiffer or lessflexible cap region as required of this class of actuator.

However constructed, the double-frustum transducer operates as shown inFIG. 7B. When one film side 74 is energized, it relaxes and pulls withless force, releasing stored elastic energy in the bias side 74 anddoing work through force and stroke. Such action is indicated by dashedline in FIG. 7B. If both film elements comprise EPAM™ film, then theactuator can move in/out or up/down relative to a neutral position(shown by solid line in each of FIGS. 7A and 7B) as indicated bydouble-headed arrow 80.

If only one active side 74/76 is provided, forced motion is limited toone side of neutral position 82. In which case, the non-active side ofthe device may simply comprise elastic polymer to provide preload/bias(as mentioned above) or EPAM™ material that is connected electrically tosense change in capacitance only or to serve as a generator to recovermotion or vibration input in the device in a regenerative capacity.

Further optional variation for frustum transducers includes provisionfor multi-angle/axis sensing or actuation. FIG. 8 shows a circular EPAM™cartridge 90 configuration with three (92, 94, 96) independentlyaddressable zones or phases. When configured as an actuator, bydifferential voltage application, the sections will expand differentlycausing cap 42 to tilt on an angle. Such a multi-phase device canprovide multi-directional tilt as well as translation depending on themanner of control. When configured for sensing, input form a rod orother fastener or attachment to the cap causing angular deflection canbe measured by way of material capacitance change.

FIG. 9A provides an assembly view of a double frustum transducer 100having a square frame member 24 with the active portion of thediaphragms 27 and the cap members 42 being round. The body frame member24 employed is solid, resembling that used in the combination orconvertible type actuator shown in FIGS. 4A-6B above; however, thedevice of FIG. 9A is a dedicated diaphragm type actuator (though it mayemploy a multi-phase structure shown in FIG. 8.) An alternativeconstruction for such an actuator is shown in FIG. 9B. Here, themonolithic frame element 24 is replaced by simple stand-off type framespacers 24″.

FIGS. 9C and 9D show perspective views of two other double frustumtransducers 104, 106, respectively, having rounded configurations forboth their outer frame 22 and output cap/disc assembly 29, 37. Spacer 24has a unitary band configuration which, when operatively assembledwithin the transducer, offsets frame elements 22 by its height dimension(rather than width dimension as with “stacked” spacers), bestillustrated in the exploded view of transducer 104 in FIG. 9C′. Theoffset frames 22 may be further fixed together or stabilized relative toeach other by screws 33 and nuts 35 or other fastening members. Thisconstruct, sometimes referred to as a “cartridge”, provides a simple,low profile form fit which can be easily integrated into a host system(e.g., pump, motor, sensor, etc.) by anchoring the frames 22 to systemhardware (not shown). By mechanically coupling the respective transducerdiscs 29, 37 (the latter having more of a ring construct) to linkages,pistons, cams, etc., the expansion and contraction of the electroactivefilm 27 can be harnessed for useful work output. More specifically,force and stroke is transmitted from the film 27 to the system load byway of the output discs. The simplicity of this form fit alsofacilitates ease of manufacture. With the EPAM cartridge made largely ofcomponents having two-dimensional shapes, unlike conventional actuatorswhich have complicated three-dimensional parts, Z-axis fabrication andassembly operations are possible, which in turn keeps manufacturingcosts low.

The design of the output disc can also be varied to accommodate theparticular application at hand. For example, the layers of disc 29 oftransducer 104 of FIG. 9C are fixed together at a central point 39 andprovided with a plurality of pass-through holes 41 which reduce airresistance undergone by the disc. Conversely, the layers of disc or ring37 are secured about their periphery and define a larger pass through 45which is ideal for applications involving fluid movement, i.e., pumpsand valves, and audio or vibration output and control or rotating shaft.Each of these configurations can be further tailored to optimizeperformance for a given application.

For example, transducer 104, when equipped with a centrally disposedoutput shaft bearing (not shown) along the central axis 39, may functionas a linear actuator which converts the reciprocating motion of disc 29to a single-direction motion for motors and pumps by way of clutches andcheck valves, respectively. Since mechanical performance directlyfollows the electrical control signal, the output speed is easilycontrolled by varying the frequency the disc's reciprocating motion.Similarly, the amplitude of the output stroke of the disc is controlledby varying electrical signal amplitude. One fundamental advantage ofthis design is its integrated shock-absorbing bearing. Unlike othertechnologies which transmit a mechanical shock from the end of theoutput shaft back to the heart of the host system, the transducer disccushions and dampens external vibrations thereby minimizing undesirableenergy transfer to the system. This inherent advantage obviates the needto use additional shock-absorbing componentry, thereby reducing the sizeand weight requirements of the system. Another advantage of thebuilt-in, completely frictionless, film-based bearing (in lieu of aconventional bearing) is that it allows the output shaft to beautomatically self-centering without additional parts or features, aswould be required when using conventional actuation technology.

Another example in which the construct of the output cap element of thetransducer can be customized to achieve desired performancecharacteristics involves the employment of a damping material disposedwithin or provided over the pass-through 45 of output cap/ring 37 oftransducer 106. With or without the damping material, the speed (i.e.,frequency) of analog output of transducer 106, with its output force andstroke proportional to an electrical input signal, can be selectivelysynched to the vibrational output of a machine to which it is interfacedin order to provide active vibration damping. The damping material inthe pass-through can provide additional sonic and/or vibrationaldamping.

FIG. 10 shows another construction variation in which the transducercomprises multiple cartridge layers 22 on each side of a double-frustumdevice 100. Individual caps 42 are ganged or stacked together. Toaccommodate the increased thickness, multiple frame sections 24 maylikewise be stacked upon one another. Also, as previously mentioned,each cartridge 22 may employ compound EPAM™ layers 10′. Either one orboth approaches together—may be employed to increase the outputpotential of the subject device. Alternatively, at least one cartridgemember in the form of the stack (on either one or both sides of thedevice) may be setup for sensing—as opposed to actuation—to facilitateactive actuator control or operation verification. Regarding suchcontrol, any type of feedback approach such as a PI or PID controllermay be employed in the system to control actuator position with veryhigh accuracy and/or precision.

FIG. 11 is a side-sectional view showing an optional output shaftarrangement with a frustum type transducer 110. Threaded bosses 112 oneither side of the cap pieces provide a means of connection formechanical output as shown. The bosses may be separate elements attachedto the cap(s) or may be formed integral therewith. Even though aninternal thread arrangement is shown, an external threaded shaft may beemployed. Such an arrangement may comprise a single shaft runningthrough the cap(s) and secured on either side with nuts in a typicaljam-nut arrangement. Other fastener or connection options are possibleas well. For example, (as shown below) the interface members may takethe form of racks, as an element of a rack-and-pinion drive system.

FIG. 12 is a side-section view of an alternate transducer 120configuration, in which, instead of employing two concave structuresfacing away from one another, the two concave/frustum sections 122 facetowards each other. The preload or bias on the EPAM™ layers forces thefilm into shape to maintain a shim or spacer 124 between caps 42.-Asshown, the spacer comprises an annular body. The caps may also includean opening in this variation of the invention as well as others. Notealso that the inward-facing variation of the invention in FIG. 12 doesnot require an intermediate frame member 24 between individual cartridgesections 22. Indeed, the EPAM™ layers on each side of the device cancontact one another. Thus, in situations where mounting space islimited, this variation of the invention may offer benefits.

A mechanical structure other than an opposing frustum structure may beused to provide the preload or bias on the EPAM™ diaphragm of anactuator. Spring-biased mechanisms are highly suitable to provide thepreload on diaphragm.

FIG. 13A provides a sectional perspective view of a coil spring-biasedsingle frustum transducer 130. Here, a coil spring 132 interposedbetween cap 42 and a baffle wall 134 associated with the frame (or partof the frame itself) biases the EPAM™ structure. A similar coil springstructure provides the preload in a double-frustum actuator 170 is shownin FIG. 13B. Here, coil spring 172 is interposed between and biases twoconcave/frustum sections 174 which face toward each other. Unlike theinward facing double-frustum transducer device 120 of FIG. 12, the cap42 a of one of the transducers is fixed or mounted, thereby providing asingle-phase actuator where the “free” transducer 174 translates twicethe distance in the biased direction (as shown in phantom) as eachtransducer of the two-phase actuator.

In the transducer 140 shown in FIG. 14, a leaf spring 142 biases the capportion of a transducer. The leaf spring is shown attached to a boss 144by a bolt 146 or a spacer captured between the bold and a nut (notshown) on the other side of the cap. The ends of the leaf are guided byrails 148.

In another transducer example 150 illustrated by FIG. 15, the EPAM™ filmmay be biased by a simple weight 152 attached to or formed integral withthe cap(s) 42. Though the device is shown tilted up for the sake ofviewing, it will typically be lie flat so that the pull of gravity onthe weight 152 symmetrical biases the transducer along a Z-axis. Inanother mode of use, the weight/mass 152 may be employed when runningthe transducer within a given frequency range as an inertial bias memberas referenced above.

Transducer Performance Characteristics

Any number of parameters of the subject transducers can be varied tosuit a given application. A non-exhaustive list includes: film type(silicone, acrylic, polyurethane, etc.); the prestrain on the EPAM™ film(magnitude, angle or direction, etc.); film thickness; active vs.non-active layers; number of layers; number of film cartridges; numberof phases; number of device “sides” and relative positioning of devicesides; the output fastener or connection means associated with the cap(be it a threaded boss, spacer, shaft, ring, disc, etc.).

Generally speaking, the polymer film materials used in accordance withthe present invention are those that deform in response to anelectrostatic force and are likely those that also have desirablepre-strain properties. The materials may be selected based on one ormore material properties or performance characteristics, including butnot limited to a low modulus of elasticity, a high dielectric constant,strain, energy density, actuation pressure, specific elastic energydensity, electromechanical efficiency, response time, operationalfrequency, resistance to electrical breakdown and adverse environmentaleffects, etc. In particular, suitable pre-strained polymers of thepresent invention have an effective modulus in the range of about 0.1 toabout 100 MPa, and more preferably in the range 0.1 to 10 MPa. Polymershaving a maximum actuation pressure (defined as the change in forcewithin a pre-strained polymer per unit cross-sectional area betweenactuated and unactuated states) between about 0.05 MPa and about 10 MPa,and particularly between about 0.3 MPa and about 3 MPa are useful formany applications. Polymers having dielectric constants between about 2and about 20, and particularly between about 2.5 and about 12, are alsosuitable. In many embodiments, the pre-strained polymers of the presentinvention have a specific elastic energy density of over 3 J/g. Polymershaving an electromechanical efficiency (defined as the ratio ofmechanical output energy to electrical input energy) greater than about80 percent are suitable for use in the present invention. Pre-strainedpolymers having response times ranging from about 0.01 milliseconds to 1second are suitable for certain transducer applications of the presentinvention. Maximum operational frequencies suitable for use with thepresent invention may be in the range of about 0.1 Hz to 1 kHz.Operational frequencies in this range allow pre-strained polymers of thepresent invention to be used in various acoustic applications (e.g.,speakers). In some embodiments, pre-strained polymers of the presentinvention may be operated at a resonant frequency to improve mechanicaloutput.

With the above parameters in mind, exemplary materials suitable for useas a pre-strained polymer include any dielectric elastomeric polymer,including silicone elastomer, polyurethane, PVDF copolymer, siliconerubbers, fluorosilicones, fluoroelastomers, and acrylic elastomers. Inone embodiment, the polymer is an acrylic elastomer comprising mixturesof aliphatic acrylate that are photocured during fabrication. Theelasticity of the acrylic elastomer results from a combination of thebranched aliphatic groups and cross-linking between the acrylic polymerchains.

It should be noted that desirable material properties for anelectroactive polymer may vary with an actuator or application. Toproduce a large actuation pressure and large strain for an application,a pre-strained polymer may be implemented with one of a high dielectricstrength, a high dielectric constant, and a low modulus of elasticity.Additionally, a polymer may include one of a high-volume resistivity andlow mechanical damping for maximizing energy efficiency for anapplication.

High-Speed Acrylic Frustum Transducers

A number of advantages have been documented with respect to use ofacrylic polymer for the transducer's dielectric film material. Acrylicpolymer is commercially available in sheet form, and offers tremendousstrain rates. As for the latter consideration, this allows for highpre-strain on the material, thereby providing the dual benefits ofthinner dielectric layers and strain-induced alignment of the materialresulting in generally improved dielectric performance. However, priorextensive testing has lead those with skill in the art to believe thatacrylic-based EPAM™ actuators are limited in performance such that workoutput drops significantly above about 100 Hz rates of actuation.Furthermore, the material is believed to limit speed response in unknownways. See, Bar-Cohen, Yoseph, Electroactive Polymer (EAP) Actuators asArtificial Muscles: Reality, Potential, and Challenges, Second Edition.Chapter 16.3.3, SPIE Press, March 2004. Overcoming the formermisconception, and rendering the latter moot, transducers according tothe present invention offer power output previously believed to beimpossible from acrylic dielectric material based transducers.

When acrylic film is employed as the dielectric component of the EPAM™,the assignee hereof discovered that by use of an appropriately weightedcap (i.e., one having its mass selected to generate resonance at orwithin a desired frequency of operation range), that the frustumarchitecture can be driven to output far more work energy thanpreviously believed possible in connection with acrylic-based EPAM™structures.

Such weighting may be accomplished in various manners. The mass of thecap may be tuned directly or indirectly by adding a body thereto. Totune it directly, material selection and/or design to a given volume(e.g., diameter, thickness, etc.) for the known density of material maybe employed. Alternatively, mass may simply be attached to the cap ofthe device as shown in FIG. 15, or by way of boss/standoff 144 and/orbolt 146 in FIG. 14.

Something unique about the frustum architecture allows it to be drivenwith large deflection upwards of 50 Hz even when employing acrylic-basedEPAM™. As commented upon above, all experience in the art had indicatedthat device amplitude dropped-off with frequency for known acrylic filmactuators. Contrary to published teaching and common knowledge, however,it is indeed possible to design certain acrylic EPAM™ actuators for highoutput between about 50 and about 100 Hz, and even greater than 100 Hz,up to about 200 Hz and beyond, potentially up to 1 kHz.

Certain acrylic-based actuators can be designed to yield maximummechanical power output using traditional mass-spring ormass-spring-damper analysis. However, the key to the applicability ofsuch analysis and/or ability to reach output, as described above, isactuator selection. The frustum architecture offers close agreementbetween actual performance and performances as modeled (i.e., withinabout 5% to 10% of each other).

Not to be bound by a particular theory, but it is believed that thisresult stems from the transducer configuration yielding output from asubstantial portion or nearly all of the available EPAM™ diaphragmmaterial expansion. Stated otherwise, this type of actuator derives itz-axis output from both the x and y components of film expansion.

Prior to this appreciation that certain acrylic transducer could beconfigured for high frequency maximum power output, the approach todeliver more power was to stack more successive EPAM™ layers or gang-upmore “cartridges” as described above. However, the inventor hereof hasinstead been able to achieve from about 5× to above 10× gains in devicepower output by clocking devices with appropriately weighted caps at ornear resonance in the ranged from about 50 to above 150 Hz.

By selecting an actuator with low losses in terms of its inherent use ofmaterial to drive device output, the system will then—and onlythen—offer performance predicted by mass-spring or mass-spring-damperresonance analysis. Other examples of actuators capable of highfrequency use when employing acrylic material are described below aswell as means of modifying known architectures to achieve the desiredpower output.

Through this use, it is possible to provide an actuator system withproperties heretofore not available. The high-frequency acrylic-basedactuator designs enable electroactive polymer devices, such asmotor-driven devices illustrated below, having power output andefficiency ratings competitive with those of conventional motor-drivendevices. Methodologies associated with such power characteristics arealso aspects of the present invention.

Frustum Transducer-Based Systems

The subject transducers can be employed in more complex assemblies thanthe component building-blocks described above. FIG. 16 provides atransducer example 160 in which a number of frustum-type transducersubunits 100 are stacked in series for stroke amplification. What ismore, an inward facing double-frustum transducers 120 offers a secondoutput phase through attachment to its frame 20. While the height ofthis member is stable due to its internal space (referenced above), theposition of its frame is mobile to provide second stage output or input.

Instead of a center stage 120, a simple spacer may be employed betweenthe outer transducers 100 for basic stroke amplification purposes. Tofurther increase stroke, then, another such stack may be set on thefirst, etc. To offer another stage of actuation, another inward-facingtransducer may be employed, etc. Yet another variation contemplatespairing an inward facing transducer with an outward facing transducer inactuator sensor pairs. Naturally, other combinations are possible aswell.

Such systems may be tuned for high-frequency performance as describedabove, but the configuration offers another potential as well. Since theframe element of the center stage is “floating,” this member may be alsobe weighted for resonance-frequency amplification purposes.Alternatively, or additionally, the internal spacer 124 of such astructure 120 as depicted in FIG. 12 could be mass-tuned as desired.

Suitable power supply modules to drive actuators according to thepresent invention include EMCO High. Voltage Corp. (California) Q, E, F,G models and Pico Electronics, Inc. (New York) Series V V units. Moretypically, rather that switching a DC power supply to obtainhigh-frequency output, a custom power will be employed. In a basicvariation, an AC transformer stepping up the voltage of 50/60 Hzwall-socket current can be employed. However, mobile systems willtypically require a more sophisticated approach involving high-frequencyDC switching applications, which circuits are becoming increasinglyaffordable/available or will be so shortly in view of their currenttrend in development.

While the inventive systems may include their subject power supplymeans, they may further comprise a number of flow control means. Thesemeans. include valves, mixers and pumps. The pumps may be utilized forfluid or gas transfer under pressure, or used to generate vacuum. Valvestructures may be fit to the pump bodies or integratedtherein/therewith.

Exemplary Pump Systems

FIGS. 17A and 17B show variations of a first pump 320 and 320′ employingdouble frustum-type actuators 100. Each device comprises a singlechamber 322 diaphragm pump. The EPAM™ actuator section may be setup forsingle or two-phase actuation as discussed above in connection with thevarious double-frustum transducer designs. The pump includes a pair ofpassive check valves 324, 326 in which movement of a membrane 328 urgedby fluid (including gas) pressure alternatively opens and closes thevalves as is readily apparent.

Pump 320′ in FIG. 17B is identical to that in FIG. 17A except that itincludes a diaphragm wall 330 in addition to the cap/diaphragm 42portion. Wall 330 provides an overall improved chamber wall interface(e.g., one that is less susceptible to elastic deformation, offeringbetter material compatibility with caustic chemicals, etc.) than theEPAM™ film itself as employed in the previous pump variation.

Like the previous devices, pump 340 shown in FIG. 18 employs passivecheck valves 324, 326. It differs from the devices, however, in that itembodies an integrated double chamber 342, 344 or double-acting pump.Again, the actuator may be a one-phase or two-phase type transducer. Inanother pump system variation, rather than employing passive checkvalves, EPAM™ valves may be employed as further described in the parentapplications herein incorporated by reference.

FIGS. 33A and 33B illustrate a pump system 1100 including an actuator102 having a frame which houses two one-way valve mechanisms 1102 a,1102 b which extend into a manifold housing 1106 having an intakemanifold 1108 a and an output manifold 1108 b. In operation, during thedown phase of actuator 1102, a diaphragm piston 1110 is pulled downwardcreating a negative pressure within chamber 1112 which causes valve 1104a to open and valve 1104 b to close. On the upward phase of actuator1102, diaphragm piston 1110 is pushed upward creating a positivepressure within chamber 1112 which causes valve 1104 a to close andvalve 1104 b to open. In this manner, fluid or gases can be pumped intointake manifold 1108 a through valve 1104 a and to within chamber 1112,after which it is pumped from the chamber through valve 1104 b and outoutput manifold 1108 b.

In all of these pumps, as in other frustum actuator designs, to offerhigh-frequency actuation when acrylic dielectric material is used, thecap itself, the intermediate layers between the cap, or the hardwareassociated with the cap defining the truncated frustum may be weightedto yield the desired resonance-type performance. Furthermore, whenso-designing systems for pumping applications, or others, loadingconditions may be accounted for—such as damping or springcharacteristics of the medium worked upon (e.g., air pushed by thepump).

Exemplary Valve System

FIGS. 19A-19C provide views of another type of flow-control system thatforms another aspect of the invention. In the perspective view of FIG.19A, a valve assembly 190 is shown in which a pair of frustum-typeactuators 192 drive a valve stem 194 for receipt within a seat 196 of ablock 198 including input/output connections 200 for flow. An end dialor knob 204 is optionally coupled to valve stem 194 to allow manualadjustment of the device when not being driven by the actuators 192.

While not necessary, operating valve assembly 190 using thehigh-frequency acrylic teachings described herein is advantageous.Lightening holes 202 in cap 42 may offer another manner of tuning themass of the body to yield desired performance.

Valve operation is accomplished by hardware as may be observed inconnection with FIGS. 19B and 19C. Specifically, valve stem 194 isadjusted relative to seat 196 along threads 204. When viewed from aboveas in FIG. 19B, pinion gears 208 and 210 are set upon one-way rollerclutch bearings 212, 214, respectively, engaging stem/shaft 194 whenrotated in opposite directions (as indicated by arrows in FIG. 19B).Suitable clutch bearings for use with the present invention may beobtain from suppliers such as McMaster-Carr. Rack members 216 and 218are set to mesh with the pinions when extended by the respectiveactuators 192. Because the racks are set beneath the pinions in the viewprovided by FIG. 19B, the racks are most easily viewed in FIG. 19C inwhich the pinion gears and clutch-bearings are now hidden by knob 204.

As shown in FIG. 19C, the rack members are spaced apart from a centerline of the housing by a gap “G”. This gap is such that neither rackmeshes with the respective pinion until advanced by the actuator. Inthis manner, knob 204 can be turned in either direction by hand tomanually effect valve adjustment. To automatically effect valveadjustment, operation of rack/pinion set 208/216 opens the valve, whileoperation of rack/pinion set 210/218 closes it (or vice versa dependingon thread direction and/or clutch direction setting). In either case,driving one actuator in a cyclical manner opens the valve, while drivingthe other closes the valve. By integrating such a valve mechanism with acontrol system, many practical applications (e.g., drug/fluid infusionor perfusion) are made available.

Regarding such a controlled valve operation, FIGS. 20A and 20B showvalve control system 190 in cross-section in closed and open states,respectively. In FIG. 20B, the travel “T” of the valve stem isillustrated. In each view, additional components that would be expectedto be included in such a system, including shaft seal 220, electricalconnections for the actuators 222, roller clutch components, etc., areshown. As pictured, the output means for the illustrated drive assemblycomprises a shaft. For use in other applications, the shaft could becoupled to a pulley, gear(s), a rocker arm, a cam, or other outputmeans.

Exemplary Motor Systems

Various motor systems are now described which utilizes the EPAMactuators of the present invention with various motion-conversionmechanisms, including rack-and-pinion drives (FIGS. 28-30) andlead-screw drives (FIGS. 31 and 32).

FIGS. 28A and 28B illustrate another configuration of a linear-to-rotarymotor architecture 600 which offers high space efficiency. Motor system600 includes a “stacked” actuator 604 which may have any number ofserially positioned EPAM transducers 606 to produce displacement of arack-610. The rack 610, pinion 612 and one-way roller clutch 614assembly is efficiently housed within a walled frame 602 stacked onactuator 604. A rod 608 rotationally mounted within frame 602 carriesthe pinion and clutch assembly. With this configuration, rod 608 isintermittently rotated in one direction. In a related variation notshown, a second pinion and clutch assembly positioned on the oppositeside of the rack equipped with a secondary set of teeth for meshing withthe second pinion provides alternative outputs. In which case, thesecond pinion-clutch assembly provides one-way movement driving thesecond output rod in the opposite rotational direction of the firstpinion-clutch assembly. As a further variation of the two-shaftapproach, the motion of the second rod is coupled to the first rod(e.g., by way of an interposed spur gear or pinion) in order wouldharness the total energy output of the actuator.

FIGS. 29A and 29B illustrate another configuration of a motorarchitecture 700 including actuator 704 having a stacked transducerassembly 706 for displacing rack 710. Rack 710 engages a pinion 712 setupon two one-way clutches 714 a, 714 b. The rack 710, pinion 712 andone-way clutches 714 a, 714 b are housed within a walled frame 702mounted on actuator 704. Output rod 708 is rotationally mounted withinframe 702 and carries the pinion and clutch assembly. The clutches areconfigured to engage and rotate rod 708 in the same direction but atdifferent phases of the transducer actuation cycle. In other words, whentransducer 706 moves in one direction, clutch 714 a is engaged to rotaterod 708 and when transducer 706 moves in the opposite direction, clutch714 b is engaged to rotate rod 708 in the same direction. Thus, insteadof the intermittent output rod rotation provided by the motor of FIGS.28A and 28B, motor 700 enables the output rod to rotate continuously.

FIGS. 30A-30C illustrate yet another motor 800 of the present inventionin which the gear assembly housed by frame 802 and the associated outputrod or shaft 806 mounted therein are sandwiched between two stackedactuators 804 a, 804 b. The actuators together alternatively actuaterack and pinion drive sets 810 a, 812 a and 810 b, 812 b, as evidencedby the slight offset between the teeth of the two pinions. A clutch 814a is configured to engage the first drive set to rotate shaft 806continuously in one direction and another clutch 814 b is configured toengage the second drive set to rotate shaft 806 continuously in theopposite direction. FIGS. 30A-30C illustrate yet another motor 800 ofthe present invention in which the gear assembly housed by frame 802 andthe associated output rod 806 mounted therein are sandwiched between twostacked actuators 804 a, 804 b.

FIGS. 31A-31C illustrate a lead-screw type motor 900 including a drum orwheel frame 902 mounted to a double frustum actuator 904 by way ofthreaded rod or screw 906 co-axial aligned with the axis of actuation ofthe actuator transducers. A slider mechanism 908 affixed to the stackedtransducer caps 910 is configured to translate the axial linear motionimposed on it by actuator 904 to rotational movement of lead-screw 906.Slider 908 has an internal tongue that matches the shape and pitch ofthe threads of screw 906 and, as such, reduces lead-screw backlash whileminimizing friction on the lead-screw 906. A one-way clutch mechanism912 coupled to wheel 902 is positioned to co-axially receive screw 906.The EPAM actuator contains a lead-screw slider 908 which maintains alinear path without rotating. Thus, upon application of voltage toactuator 904, as illustrated in FIG. 31B, the actuator's displacementmoves slider 908 in a first linear direction (e.g., downward) which inturn forces screw 906 to rotate in a first rotational direction (e.g.,counter-clockwise). As actuator 904 returns through its stroke, asillustrated in FIG. 31C, slider 906 moves in the opposite direction(e.g., upward) thereby rotating lead-screw 906 in a second rotationaldirection (e.g., clockwise) thereby creating an oscillating rotationwith a given angular displacement. One-way clutch 912 in turn convertsthe screw's oscillating rotational movement into pure uni-directional(e.g., counter-clockwise) rotational movement of wheel 902.

FIGS. 32A-32C illustrate a double clutch lead-screw motor 1000 includinga drum or wheel frame 1002 having a centrally-disposed drive shaft 1014about which a double frustum actuator 1004 is positioned. An axialcoupler 1008, including a two-way clutch mechanism 1016, affixed andlinearly driven by actuator 1004 interfaces the internally facing endsof a right hand pitched lead-screw 1010 a to a left hand pitched leadscrew 1010 b therein, where drive shaft 1014 is centrally positionedwithin the lead screws. Each output end of the screws is received by aone-way clutch 1012 a, 1012 b, respectively. This configuration createsa double-clutch effect to provide rotation of the screws with bothstrokes of the EPAM actuator 1004. Upon application of voltage toactuator 1004, as illustrated in FIG. 32B, the actuator's displacementmoves coupler 1008 in a first linear direction (e.g., downward) which inturn forces screw 1010 a to rotate in a first rotational direction(e.g., counter-clockwise) and screw 1010 b to rotate in a second,opposite rotational direction (e.g., clockwise). As actuator 1004returns through its stroke, as illustrated in FIG. 32C, coupler 1008moves in the opposite direction (e.g., upward) thereby rotatinglead-screw 1010 a in a second rotational direction (e.g.,counter-clockwise) and rotating lead-screw 1010 b in the firstrotational direction (e.g., clockwise). The screws' oscillatingrotational movement which is translated to shaft 114 is converted intopure unidirectional (e.g., counter-clockwise) rotational movement of bythe one-way clutches 1012 a, 1012 b.

The pitch of the lead-screws can be non-constant to compensate directlyfor force/stroke profiles generated by EPAM actuators. Similarly,through lead-screw pitch design, different torque ratios can be designedfor the actuators. The co-axial alignment between the lead screws andthe EPAM axis provides greater flexibility in the form factor density orthe motor allows the EPAM actuator to be packaged either inside oroutside the rotating output component (e.g., wheel).

One skilled in the art will recognize a plethora of combinations of thesubject EPAM actuated motors to selectively drive any number of outputmembers in a desired direction.

Exemplary Lighting Systems

As mentioned above, the EPAM™ actuators of the present invention alsohave application in the lighting industry, in the context of both wallsocket (120V/60 Hz power) driven/stationary lighting systems andbattery-operated/mobile lighting systems.

FIGS. 26A and 26B illustrate a schematic representation of an exemplaryarrangement of such a lighting system 500. Here, a single-phase, singlefrustum-type EPAM™ actuator 502 is employed which includes a diaphragm508 affixed to a frame 510. The diaphragm may be weighted with a cap 42having a selected mass to achieve the desired resonance frequency of thediaphragm. The diaphragm may also be pre-biased upwards by any suitablebiasing means (not shown), e.g., a spring, to enhance performance of theactuator. Actuator 502 is in positional contact with or otherwisemechanically coupled by way of a stem or rod 522 to a light source 506,which is any suitable light source depending on the application at hand.Upon application of a voltage to the actuator via lead lines 520 coupledto a power supply (not shown), diaphragm 508 relaxes and is moved in theZ-axis along with rod 522 and light source 506 are also displaced in thesame direction, as illustrated in FIG. 26B.

Positioned about the light source is a reflector assembly which includesone or more reflectors, e.g., mirrors, or lenses. While any number ofreflectors may be used, here, two reflectors are used—a primaryreflector 512 positioned between actuator 502 and light source 506 andabout the Z-axis to create the primary reflecting surface, and asecondary reflector 514 positioned on the opposite side of the lightsource. This arrangement provides a reflector “ring”, however, any othersuitable arrangement of reflectors and the resulting construct may beemployed with the present invention. In the illustrated embodiment,secondary reflector 514, unlike primary reflector 512, is mechanicallycoupled to light source 506, and therefore exhibits no movement relativeto light source 506 (i.e., secondary reflector is displaced togetherwith the light source). In other embodiments, the light source and thesecondary reflector may be stationary and the primary reflector movablerelative thereto. The latter configuration is advantageous where thelight source/secondary reflector combination is heavier than the primaryreflector or where type of light source used is particularly sensitiveto vibrational movement such as a filament type incandescent bulb.

In any case, primary reflector 512 is designed to do the bulk of thevariable direction ray reflection. For example, at least half of thelight emitted from light source 506 is designed to hit primary reflector512 first and be reflected in the desired direction without thenecessity of being diverted by secondary reflectors. Secondary reflector514 is responsible for diverting rays emitted from light source 506 inthe upper hemisphere back down to primary reflector 512 in aconcentrated ray. Depending on the application, a tertiary reflector orreflectors (not shown), which are also stationary relative to theprimary reflector, may be employed to assist in redirecting stray raysfrom the light source. In any case, the resulting reflected light ray ismade up of substantially all available light provided by light source506.

By operating EPAM actuator 502 between the high and low positions, asshown in FIGS. 26A and 26B, respectively, (or between any number ofpositions therebetween) at a frequency which is greater than thatperceptible by the human eye, i.e., >25 Hz, light source 506 is movedrelative to the primary reflector 512. The variable focal length to thereflector ring creates the ability to change the overall focus of theemitted light. As illustrated, broader band light rays 516 are providedwhen the light source is in the “low” position and narrower band lightrays 518 are provided when the light source is in the “high” position.

Any arrangement of actuators, light sources and reflectors/lenses may beemployed in the subject systems where the relative motion between thelight source(s) and reflector(s)/ lens(es) is adjusted at a high rate ofspeed. As such, an alternative arrangement to the one illustrated inFIGS. 26A and 26B is one that couples the reflector assembly, or one ormore reflectors/lenses thereof, to the EPAM actuator to adjust itsposition relative to the light source(s). Alternatively, both the lightsource as well as the reflector assembly may be driven by their ownactuator to provide more control over the direction and diffusion of thelight vector. Individual reflectors/lenses or groups of reflectors/lensmay be driven or moved independently of each other to providemulti-faceted directionality to the light rays. Furthermore, any numberEPAM diaphragms may be used to construct the subject actuators. Forexample, actuators having a stacked diaphragm configuration may be usedto increase maximum displacement of a light source and/or reflectorassembly.

Still further, a multi-phase EPAM actuator may be employed to provide aunique lighting pattern, e.g., a strobe effect, flashing, etc. Forexample, a single, variable-phase actuator, such as the type illustratedin FIG. 8, may be used to displace the light source and/or thereflector/lens assembly to change directionality of the light rays wherethe directionality depends on the “phase” in which the actuator isoperated. This is illustrated in FIGS. 27A and 27B, where selectedportions of actuator the multi-phase diaphragm 536 of actuator 532having frame 534 can be activated to change the direction of thereflected rays. The diaphragm may have any number of phases to providethe desired effect. For example, FIGS. 27A and 27B show actuator 532acting in a bi-lateral manner to provide left-directed rays 538 andright-directed rays 540. A greater number of phases may be employed toproduce a rotating light effect, such as those used on emergencyvehicles, or a “wobble” pattern.

This technology may be used to amplify any and all types of light in anyand all types of lighting applications—standard lighting applicationsdriven by 120V AC outlet power as well as mobile lighting applications,such as in any self-propelled vehicle (automobiles, planes, ships),manually-propelled vehicle (bicycles) and battery-operated application(flash lights, etc.).

In home lighting applications, for example, the system may be designedto have a volume of a standard light bulb. The actuator may be a singlephase diaphragm stack approximately 35 mm in diameter (approximates thatof a standard light bulb size). In one variation, a resonant frequencytransformer (RFT) may be used to power the system directly off of a 120VAC-60 Hz power line. By using an RFT rather than a standardtransformer, the actuator device appears as a purely resistive loadrather than as a capacitive and resistive load with an undesirable powerfactor. In a basic form, the power supply is a standard high voltagetransformer converting 120VAC 60 Hz into 2500VAC, 60 Hz. This woulddrive the EPAM actuator at 120 Hz because the effective 60 Hz waveformhas two maximum peaks and thus yields two displacements per cycle. Atthis frequency, the occurrence of flicker or beat interference fromother devices would be minimized if unlikely to occur. Moreover, such aconfiguration optimizes the ratio of input voltage to diaphragmdisplacement.

Those skilled in the art will appreciate than any number of lightingsystem architectures of the present invention may be employed for mobilelighting applications. An aspect of the systems is achieve an efficientinput voltage-to-diaphragm displacement ratio by providing or tuning theEPAM actuators to operate at their natural frequency. Suitable powersupplies for such mobile applications are configured to generate highoscillating voltages from a DC power source, such as a high voltagetransistor array. Any increase in space requirements of the power supplyare offset by the reduced requirement for bulky chemical energy storage,i.e., batteries, as the power supply is lighter than most batteries,making the overall system lighter and more efficient.

As for light sources, any type may be employed with the subject systems,depending on the desired lighting effect. For example, for directedlight, light-emitting diodes (LEDs) may be employed, whereasconventional incandescent lights may be used to produce diffuse light.Short arc high intensity discharge light sources are the closest topoint light sources and are therefore easily usable in a high efficiencylight systems of the present invention.

Known Transducers Modified for High-Speed Performance

FIG. 21A shows a known actuator 1200 that may be modified for useaccording an aspect of the present invention. The “bow” type actuator1200 is a planar mechanism comprising a flexible frame 1202 whichprovides mechanical assistance to improve conversion from electricalenergy to mechanical energy for a polymer diaphragm 1206 attached to theframe 1202. The frame 1202 includes six substantially rigid strutmembers 1204 connected at joints 1205. The struts 1204 and joints 1205provide mechanical assistance by coupling polymer deflection in a planardirection 1208 into mechanical output in a perpendicular planardirection 1210. More specifically, the frame 1202 is arranged such thata small deflection of the polymer 1206 in the direction 1208 improvesdisplacement in the perpendicular planar direction 1210.

Attached to opposing (top and bottom) surfaces of the polymer 1206 areelectrodes 1207 (bottom electrode on bottom side of polymer 1206 notshown) to provide a voltage difference across a portion of the polymer1206. Polymer 1206 is configured with different levels of pre-strain inits orthogonal directions. More specifically, electroactive polymer 1206includes a high pre-strain in the planar direction 1208, and little orno pre-strain in the perpendicular planar direction 1210. Thisanisotropic pre-strain is arranged relative to the geometry of the frame1202. More specifically, upon actuation using electrodes 1207, thepolymer contracts in the high pre-strained direction 1208. With therestricted motion of frame 1202 and the lever arm provided by members1204, this contraction helps drive deflection in the perpendicularplanar direction 1210. Thus, even for a short deflection of polymer 1206in high pre-strain direction 1208, frame 202 bows outward in direction1210. In this manner, a small contraction in the high pre-straindirection becomes a larger expansion in the relatively low pre-straindirection.

Using the anisotropic pre-strain and constraint provided by frame 1202,bow actuator 1200 allows contraction in one direction to enhancemechanical deflection and electrical to mechanical conversion inanother. In other words, a load 1211 attached to the bow actuator iscoupled to deflection of polymer 1206 in two directions—direction 1208and 1210. Thus, as a result of the differential pre-strain of polymer1206 and the geometry of the frame 1202, the bow actuator is able toprovide a larger mechanical displacement and mechanical energy outputthan an electroactive polymer alone for common electrical input.

The pre-strain in EPAM™ 1206 and constraint provided by frame 1202 mayalso allow the bow-type actuator to use lower actuation voltages for thepre-strained polymer for a given deflection. As bow actuator 1200 has alower effective modulus of elasticity in the low pre-strained direction1210, the mechanical constraint provided by frame 1202 allows the bowactuator to be actuated in direction 1210 to a larger deflection with alower voltage. In addition, the high pre-strain in direction 1208increases the breakdown strength of the polymer 1206, permitting highervoltages and higher deflections for the actuator 1200.

In one variation, the bow actuator may include additional components toprovide mechanical assistance and enhance deflection. By way of example,springs (not shown) may be attached to bow actuator 1200 to enhancedeflection in direction 1210. The springs load the actuator such thatthe spring force exerted by the spring(s) opposes resistance provided byan external load. In some cases, the springs provide increasingassistance for bow actuator 1200 deflection. In addition, pre-strain maybe increased or made more uniform to enhance deflection by relying onspring tension instead for shaping the device. The load may also becoupled to the rigid members 1204 on top and bottom of the frame 1202rather than on the rigid members of the side of the frame 1202.

FIG. 21B illustrates another known actuator 1300 that may be suitablymodified for use the present invention. “Bowtie” actuator 1300 includesa polymer diaphragm 1302 arranged in a manner which causes a portion ofthe polymer to deflect in response to a change in electric field.Electrodes 1304 are attached to opposite surfaces (only the foremostelectrode is shown) of the EPAM™ material and cover all of a substantialportion of polymer 1302. Two stiff spar or base members 1308 and 1310extend along opposite edges 1312 and 1314 of polymer 1302. Strutflexures 1316 and 1318 are situated along the remaining edges of polymer1302. Flexures 1316 and 1318 improve conversion from electrical energyto mechanical energy for actuator 1300.

Flexures 1316 and 13.18 couple polymer diaphragm 1302 deflection intodeflection in another direction. In one embodiment, each of the flexuresrests at an angle about 45 degrees in the plane of polymer 302. Uponactuation of the device, expansion of EPAM™ material 1302 in direction1320 causes stiff members 1308 and 1310 to move apart, as indicated byarrows. In addition, expansion of the polymer in direction 1322 causesflexures 1316 and 1318 to straighten, and concurrently separating thebase members 1308 and 1310. In this manner, actuator 1300 couplesexpansion of polymer 1302 in both planar directions 1320 and 1322 intomechanical output in direction 1320.

The polymer may, again, be configured with different levels ofpre-strain in orthogonal directions 1320 and 1322. Such anisotropicpre-strain is arranged relative to the geometry of flexures 1316 and1318. More specifically, polymer 1302 may include a higher pre-strain indirection 1320, and little or no pre-strain in the perpendicular planardirection 1322.

FIG. 21C shows yet another known type of actuator 1400 that employs theEPAM™ material with such efficiency as to make it amenable forhigh-frequency use according to the present invention. Specifically, a“spider” type actuator 1400, superficially resembling to a Moonie orcymbal type piezoelectric actuator, employs a radially symmetric shellor frame comprising a top portion 1402 having struts 1406 extendingradially outward and downward from a base 1416, and a bottom portion1404 having struts 1408 extending radially outward and upward from abase 1418. The concave sides of the shell portions 1402, 1404 face eachother where the respective strut ends meet or coapt at a commoninterface 1410 and are attached to the edge of a flat EPAM™ diaphragm1412 or an intermediate ring membrane. Attached to opposing (top andbottom) surfaces of the polymer diaphragm 1412 are electrodes (notshown) to provide a voltage difference across a portion of the polymer1412. Upon application of a voltage to the electrodes, the strutsprovide mechanical output by transferring polymer deflection in a planardirection 1414, 1422 into mechanical compression in a directionorthogonal 1420 to the plane of the diaphragm 1412.

The polymer material of the spider actuator may be configured with anevenly distributed pre-strain or may be configured with different levelsof pre-strain. For example, in one embodiment, interface 1410 defines acircle where the pre-strain is distributed evenly and radiallythroughout the polymer 1412. With embodiments where pairs ofdiametrically opposed struts have a length which is different from thatof other pairs of diametrically opposed struts, a non-circular (e.g.,oval, elliptical, etc.) interface 1410 is formed. Using a non-circularshell configuration with a polymer having an unrestrained or naturalcircular shape will result in directional differences in pre-strain. Assuch, the relative lengths of the struts may be selected to achieve thedirectional pre-strain desired.

Another “spider” type actuator 1500 for high-frequency applications isillustrated in FIG. 21D. Actuator 1500 includes a similar construct tothat of FIG. 21C, however here, the frame includes the strut structurehaving top and bottom portions 1502, 1504 as well as planar frames 1518,1520. Each shell portion includes struts 1506, 1508, respectively,extending radially from a base 1510, 1512 where opposing top and bottomstruts ends coapt at an interface 1514 sandwiched between planar frames1518, 1520. Extending and sandwiched between the strut ends is a flatEPAM™ diaphragm having top and bottom electrodes (top electrode 1522 isviewable in FIG. 22D) covering a substantial portion of the top andbottom surfaces of polymer 1516. Upon application of a voltage to theelectrodes, the struts provide mechanical output by transferring polymerdeflection in a planar direction 1524, 1526 into mechanical compressionin a direction orthogonal 1528 to the plane of the diaphragm.

For use according to the present invention, FIGS. 22A-22D show modifiedversions of the above-referenced actuations in FIGS. 21A-21D. Whilecertain modifications are required according to the present invention asdescribed below, numerous optional variations ranging from changing themanner of pre-strain described above, substituting pivots for flexures,altering straight-line geometry to curvilinear forms, increasing ordecreasing the number of frame or (i.e., flexure and/or “stiffmembers”), varying the length of the shell struts, altering the EPAM™material shape or aspect ratio (e.g., from circular to elliptical, tosquare, etc.), or other modification is contemplated. However, thecharacteristics of the system should not be so changed in form as tosubstantially lose geometric efficiency causing the actuators to nolonger perform substantially as expected when employing acrylic-basedEPAM™ and clocked at higher speeds as contemplated herein.

As for modifying the subject devices according to the present invention,this is accomplished through perimeter or extremity weighting of one ormore device frame elements. In FIG. 22A, these weight or mass elementsare shown as optionally comprising slugs 1212. In FIG. 22B, these weightor mass elements are shown as optionally comprising bars 1313 insertedin the base members. In FIGS. 22C and 22D, the weight or mass elementsare shown as discs 1424, 1524, respectively, attached to the top andbottom shell faces or bases. Still further, these various bow, bowtieand spider type actuators may be employed as high-speed acrylic-baseddevices through weighting associated with output connection features(not shown), such as rods, racks, gears, etc.

Bi-Stable Transducers

Another class of actuators according to the present invention offers yetanother high-efficiency configuration amenable to high-speed use withacrylic EPAM™ material. They may also be advantageously employed withsilicone as the dielectric material or in other transducerconfigurations. Advantageously, they include no hinge or flex pointsprone to wear or fatigue as in the variations discussed directly above.

More specifically, FIGS. 23A-23C show a saddle-shaped actuator runthrough various stages of its stroke—at least on one side of it unstableequilibrium point. In its unpowered state, preload upon EPAM™ diaphragm400 causes frame to essentially controllably buckle or collapse into thesaddle-shape actuator configuration 404 shown in FIG. 23 a.Mathematically, the form is well described using sine/cosine functions.

When the EPAM™ diaphragm is energized, its expansion (cutting across allthree directional axes) allows stress in the frame to relax and assumean intermediate configuration 404′ as shown in FIG. 23B. Upon maximumpolymer material expansion, the frame is able to substantially flattento configuration 404″ shown in FIG. 23C. In a completely flat state,frame 402 is in an unstable equilibrium position (i.e., without powerapplied thereto to maintain the position).

Depending on the drive configuration associated with the frame, theactuator can be pushed-over or employ its own inertia to continue andactuate with arms/wings 406/408 reversing direction from that shown inFIGS. 23A and 23B. In this manner, the actuator offers two stablesaddle-shaped equilibrium configurations or positions. Otherwise, the“flapping” action of the transducer can be constrained to one side ofthe unstable equilibrium position, rather than applying the optionalbi-stable maximum-travel/stroke potential.

FIG. 24 illustrates a constrained application in which two such“flapper” actuators 410, 412 are set across from each other. Connectedor secured at ends 406, with one end anchored at point “A”, actuationforces between the bodies are balanced (or at least substantially-so) inorder to yield output along the axis of the double arrow. Alternatively,mechanical energy may drive transducer assembly 414 along the doublearrow so that it serves as a generator setup.

Of course, other approaches may be employed to utilize the actuatoroutput. When only one actuator 410 is to be used, “U” shaped yokes (orone yoke across from anchor points) can be attached to each of theopposite end pairs 406/408. As with the EPAM™ cartridges employed above,individual actuators may be staked to operate in parallel, rather thanopposite one another as shown in FIG. 24. Still, further, actuators maybe ganged in series to amplify stroke. Yet another example is providedbelow, though still others are possible as well.

However device output is harnessed, one or more such saddle-shapeddevice can be set-up for high-speed actuation, even using acrylic-basedEPAM™ material. As with the other exemplary embodiments capable of suchuse, multiple-axis expansion of the polymer drives ultimate deviceoutput. In this particular case, the mass or weight tuning of the systemto achieve the desired performance may occur (as in the examples inFIGS. 23A and 23B) by tuning the mass of the frame. Frame 402 may bethickened, include inset or clamp-on weights or be designed or modifiedotherwise to reach its target mass attributes. The mass/weight may beapplied symmetrically or asymmetrically. The design will depend on theoverall plan-form configuration of the actuator. Those shown aresubstantially square in shape. However, other forms are contemplatedsuch as more rectangular, rhomboid, or rounded (including elliptical andcircular) forms as well as others.

As for application, FIGS. 25A and 25B illustrate a saddle-shapedactuator 410 connected to a pair of wings 420 to offer a bird orbat-like system 440. The detail view in FIG. 25A highlights a simple andefficient connection structure. FIG. 25B illustrates the mechanicalcreature flapping in a time-lapse fashion with multiple wing “beats”

Returning to FIG. 25A, upper and lower flexible struts 422, 424 connectwing foil section 426 to the actuator. On each side of the system, thelower struts 426 connect to opposite ends 406 and the upper struts 422connect to opposite ends 408 of the actuator. A spring 428 provides biasforce to the system and also helps form the actuator into the shapedesired as well as help “tune” the system to a particular resonancefrequency. Electrical leads 430 (that could otherwise lead to anintegral/portable power source) connect the actuator to an externalpower supply in the prototype model shown. With optimization andrefinement, the system shown in FIGS. 25A and 25B holds promise forachieving flight possibilities at high or low frequency, and with bodiesranging from a wing span of several inches to several meters. Givenappropriate hardware and software control, it may be programmed forgliding as well as flapping flight. Together with other controlfeatures, optional electrical solar power and regenerative powermanagement while gliding, etc. as may be applied by those with skill inthe art, this mechanized flight system offers potential to surpass evenits natural counterparts in endurance, range and longevity.

Transducer Fabrication

Regardless of the configuration selected for the subject transducers,various manufacturing techniques are advantageously employed.Specifically, it is useful to employ mask fixtures (not shown) toaccurately locate masks for patterning electrodes for batchconstruction. Furthermore, it is useful to employ assembly fixtures (notshown) to accurately locates multiple parts for batch construction.Other details regarding manufacture may be appreciated in connectionwith the above-referenced patents and publication as well as generallyknow or appreciated by those with skill in the art.

Methods

Methods associated with the subject devices are contemplated in whichthose methods are carried out with EPAM™ actuators. The methods may beperformed using the subject devices or by other means. The methods mayall comprise the act of providing a suitable transducer device. Suchprovision may be performed by the end user. In other words, the“providing” (e.g., a pump, valve, reflector, etc.) merely requires theend user obtain, access, approach, position, set-up, activate, power-upor otherwise act to provide the requisite device in the subject method.

Kits

Yet another aspect of the invention includes kits having any combinationof devices described herein—whether provided in packaged combination orassembled by a technician for operating use, instructions for use, etc.

A kit may include any number of transducers according to the presentinvention. A kit may include various other components for use with thetransducers including mechanical or electrical connectors, powersupplies, etc. The subject kits may also include written instructionsfor use of the devices or their assembly.

Instructions of a kit may be printed on a substrate, such as paper orplastic, etc. As such, the instructions may be present in the kits as apackage insert, in the labeling of the container of the kit orcomponents thereof (i.e., associated with the packaging orsub-packaging) etc. In other embodiments, the instructions are presentas an electronic storage data file present on a suitable computerreadable storage medium, e.g., CD-ROM, diskette, etc. In yet otherembodiments, the actual instructions are not present in the kit, butmeans for obtaining the instructions from a remote source, e.g. via theInternet, are provided. An example of this embodiment is a kit thatincludes a web address where the instructions can be viewed and/or fromwhich the instructions can be downloaded. As with the instructions, thismeans for obtaining the instructions is recorded on suitable media.

Variations

As for other details of the present invention, materials and alternaterelated configurations may be employed as within the level of those withskill in the relevant art. The same may hold true with respect tomethod-based aspects of the invention in terms of additional acts ascommonly or logically employed. In addition, though the invention hasbeen described in reference to several examples, optionallyincorporating various features, the invention is not to be limited tothat which is described or indicated as contemplated with respect toeach variation of the invention. Various changes may be made to theinvention described and equivalents (whether recited herein or notincluded for the sake of some brevity) may be substituted withoutdeparting from the true spirit and scope of the invention. Any number ofthe individual parts or subassemblies shown may be integrated in theirdesign. Such changes or others may be undertaken or guided by theprinciples of design for assembly.

Also, it is contemplated that any optional feature of the inventivevariations described may be set forth and claimed independently, or incombination with any one or more of the features described herein.Reference to a singular item, includes the possibility that there areplural of the same items present. More specifically, as used herein andin the appended claims, the singular forms “a,” “an,” “said,” and “the”include plural referents unless the specifically stated otherwise. Inother words, use of the articles allow for “at least one” of the subjectitem in the description above as well as the claims below. It is furthernoted that the claims may be drafted to exclude any optional element. Assuch, this statement is intended to serve as antecedent basis for use ofsuch exclusive terminology as “solely,” “only” and the like inconnection with the recitation of claim elements, or use of a “negative”limitation. Without the use of such exclusive terminology, the term“comprising” in the claims shall allow for the inclusion of anyadditional element—irrespective of whether a given number of elementsare enumerated in the claim, or the addition of a feature could beregarded as transforming the nature of an element set forth n theclaims. For example, adding a fastener or boss, complex surface geometryor another feature to a “diaphragm” as presented in the claims shall notavoid the claim term from reading on accused structure. Statedotherwise, unless specifically defined herein, all technical andscientific terms used herein are to be given as broad a commonlyunderstood meaning as possible while maintaining claim validity.

In all, the breadth of the present invention is not to be limited by theexamples provided. That being said, we claim:

1. An transducer comprising: an open frame and at least two diaphragmlayers, each diaphragm layer comprising an electroactive polymermaterial extending within the frame, wherein central portions of thediaphragm layers are coupled together and wherein the diaphragm layersare free to actuate in at least two component directions uponapplication of a voltage across the electroactive polymer material. 2.The transducer of claim 1 wherein the remaining portions of onediaphragm layer are spaced from the remaining portions of the otherdiaphragm layer to form a double-frustum configuration.
 3. Thetransducer of claim 1 wherein the coupled-together central portionsdefine a cap structure.
 4. The transducer of claim 1 wherein the capstructure has a disc configuration having a least one pass-through holetherethrough.
 5. The transducer of claim 1 wherein the electroactivepolymer material comprises silicone.
 6. The transducer of claim 1wherein the electroactive polymer material comprises acrylic.
 7. Thetransducer of claim 1 wherein the electroactive polymer materialcomprises a dielectric elastomer.
 8. The transducer of claim 1 whereinoutput motion of the diaphragm layers has a frequency with the rangefrom about 0.1 Hz to about 1 kHz.
 9. The transducer of claim 1 whereinactuation of the diaphragm is used to convert linear motion into rotarymotion.
 10. The transducer of claim 1 wherein actuation of the diaphragmis used to convert linear motion into rotary motion.
 11. The transducerof claim 1 wherein actuation of the diaphragm is used to control linearor rotary movement.
 12. The transducer of claim 1 wherein actuation ofthe diaphragm is used to control fluid movement.